Repositioning of articles between different positions within an intermittently accessible space

ABSTRACT

Articles, such as components of an injection-molded multi-component product, are repositioned within a space, such as the space between mold parts, that is accessible for repositioning only during a series of periods, such as open-mold periods, that are separated by intervals of less accessibility for repositioning, such as closed-mold intervals by (a) moving a first article, such as a first component of a first multi-component product, from a first position within the space to outside of the space during a first such period; and (b) moving a second identical article, such as a first component of a second multi-component, from outside of the space to a second position within the space during the first such period. Both the movement of the first article and the movement of the second article are by means of a common vehicle, such as a common robot arm. In another aspect, an article is repositioned by (a) moving the article from a first position within the space to outside of the space during a first such period; and (b) during a second such period after an interval of less accessibility that is subsequent to the first period, moving the article from outside of the space to a second position within the space.

CROSS-REFERENCE TO RELATED APPLICATION

This is a division of application No. 08/914,569 filed Aug. 19, 1997 nowU.S. Pat. No. 6,086,808.

BACKGROUND OF THE INVENTION

The present invention pertains to repositioning articles within a spacethat is accessible for said repositioning only during a series ofperiods that are separated by intervals of less accessibility for saidrepositioning than during said periods.

For various manufacturing and other processes it is desirable toreposition an article within a given space between processing steps.When an article has to be moved from a first processing position withinthe given space to a second processing position within the given space,but such movement is impeded or made impossible by changes in theaccessibility of the given space for said repositioning that arenecessitated by one or more aspects of the process, such repositioningtypically is carried out during those periods when the given space ismore accessible for said repositioning but not during those intervalswhen the given space is less accessible for repositioning. As a result,such accessible periods may be of such an extended duration as to slowdown or halt the overall process and thereby make the overall processless efficient.

For example, in a process for injection molding a multi-componentproduct a first component formed in a first mold cavity by injectionmolding is repositioned to a second mold cavity in which a secondcomponent of the product is formed in combination with the firstcomponent by injection molding the second component. Such repositioningwithin the space between the mold parts can be accomplished only duringa period of time when the mold is open, and typically is accomplished bymeans of a robot arm that (a) attaches onto the first component in thefirst mold-cavity position with an attachment mechanism on the robotarm, (b) moves the attached first component from the first mold-cavityposition to a second mold-cavity position and (c) releases the firstcomponent from the attachment mechanism. However, the time required forattaching onto the first component, moving the attached first componentfrom the first mold-cavity position to the second mold-cavity positionand releasing the first component is greater than the time required formerely attaching onto a molded article and moving the attached moldedarticle from its mold-cavity position when repositioning of the moldedarticle is not required, whereby such repositioning from the firstmold-cavity position to the second mold-cavity position within the spacebetween the mold parts makes it necessary to keep the mold open for alonger period of the time so that the space between the mold parts willbe accessible until said repositioning is completed.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a method of repositioningarticles within a space that is accessible for said repositioning onlyduring a series of periods that are separated by intervals of lessaccessibility for said repositioning, comprising the steps of:

(a) during a first said period, moving a first article from a firstposition within said space to outside of said space; and

(b) during the first period, moving a second article from outside ofsaid space to a second position within said space;

wherein said movement of the first article and said movement of thesecond article are by means of a common vehicle.

By using the same means, such as a common vehicle, to move the secondarticle from outside of said space to the second position and then movethe first article from the first position within said space to outsideof said space during the same period of accessibility, the combined timerequired for repositioning both articles is reduced significantly and aseparate repositioning step that would be required if both the movementof the second article to the second position and the movement of thefirst article from the second position were not accomplished by samemeans is eliminated.

In another aspect, the present invention provides a method ofrepositioning articles within a space that is accessible for saidrepositioning only during a series of periods that are separated byintervals of less accessibility for said repositioning, comprising thesteps of:

(a) during a first said period, moving a first article from a firstposition within said space to outside of said space; and

(b) during the first period, moving an identical second article fromoutside of said space to a second position within said space.

In a further aspect, the present invention provides a method ofrepositioning articles within a space that is accessible for saidrepositioning only during a series of periods that are separated byintervals of less accessibility for said repositioning than during saidperiods, comprising the steps of:

(a) during a first said period, moving a first article from a firstposition within said space to outside of said space; and

(b) during a second said period after a said interval of lessaccessibility that is subsequent to the first period, moving the firstarticle from outside of said space to a second position within saidspace.

Accordingly, the repositioning method of the present invention does notrequire that the space be accessible for a period of time greater thanthe time required for attaching onto a first article and moving theattached first article from the first position within said space,whereby such repositioning method decreases the time during which thespace must be accessible for said repositioning in relation to theaccessible time required in the prior art repositioning method describedabove. Preferably, the first period is separated from the second periodby only one interval of less accessibility.

The repositioning methods of the present invention are particularlyapplicable for repositioning articles within a space between mold partsthat defme a plurality of mold cavities when the mold is closed, whereinsaid space is accessible for said repositioning only during a series ofopen-mold periods that are separated by closed-mold intervals ofinaccessibility for said repositioning.

Additional features of the present invention are described withreference to the detailed description of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWING

FIGS. 1A through 1F schematically illustrate a series of steps in aninjection molding process in which articles are repositioned inaccordance with a first embodiment of the method of the presentinvention during a first period of accessibility.

FIGS. 2A through 2F schematically illustrate a subsequent series ofsteps in the injection molding process in which articles arerepositioned in accordance with the first embodiment during a secondperiod of accessibility.

FIGS. 3A through 3F schematically illustrate a further subsequent seriesof steps in the injection molding process in which articles arerepositioned in accordance with the first embodiment during a thirdperiod of accessibility.

FIGS. 4A through 4F schematically illustrate a series of steps in aninjection molding process in which articles are repositioned inaccordance with a second embodiment of the method of the presentinvention during a first period of accessibility.

FIGS. 5A through 5F schematically illustrate a subsequent series ofsteps in the injection molding process in which articles arerepositioned in accordance with the second embodiment during a secondperiod of accessibility.

FIGS. 6A through 6F schematically illustrate a further subsequent seriesof steps in the injection molding process in which articles arerepositioned in accordance with the second embodiment during a thirdperiod of accessibility.

FIGS. 7A through 7F schematically illustrate a still further subsequentseries of steps in the injection molding process in which articles arerepositioned in accordance with the second embodiment during a fourthperiod of accessibility.

FIGS. 8A through 8F schematically illustrate a series of steps in aninjection molding process in which-articles are repositioned inaccordance with a third embodiment of the method of the presentinvention during a first period of accessibility.

FIGS. 9A through 9F schematically illustrate a subsequent series ofsteps in the injection molding process in which articles arerepositioned in accordance with the third embodiment during a secondperiod of accessibility.

FIGS. 10A through 10F schematically illustrate a further subsequentseries of steps in the injection molding process in which articles arerepositioned in accordance with the third embodiment during a thirdperiod of accessibility.

FIGS. 11A through 11F schematically illustrate a still furthersubsequent series of steps in the injection molding process in whicharticles are repositioned in accordance with the third embodiment duringa fourth period of accessibility.

FIGS. 12A through 12F schematically illustrate yet another subsequentseries of steps in the injection molding process in which articles arerepositioned in accordance with the third embodiment during a fifthperiod of accessibility.

FIGS. 13A through 13D schematically illustrate the operation of a robotmechanism when the articles attached thereto have been removed from thespace between the mold parts in accordance with the third embodiment, asshown in view F of FIGS. 8 through 12.

FIGS. 14A through 14L schematically illustrate a series of steps in aninjection molding process in which articles are repositioned withinspaces between different pairs of separated mold parts of a stack moldin accordance with a fourth embodiment of the method of the presentinvention during a first open-mold period of accessibility to the spacebetween one pair of mold parts, as shown in FIGS. 14A through 14F, andduring a second open-mold period of accessibility to the space betweenanother pair of mold parts, as shown in FIGS. 14G through 14L.

DETAILED DESCRIPTION

Referring to FIGS. 1A through 1F, 2A through 2F and 3A through 3F, afirst embodiment of the repositioning method of the present invention isperformed during an injection molding process in which a multi-componentproduct is produced by injection molding a first component of theproduct in a first mold cavity 10 and repositioning the first componentto a second mold cavity 12 in which a second component of the product isformed in combination with the first component by injection molding thesecond component. The first component of the product is referred to thefollowing description of this first embodiment as an “article”. Thefirst mold cavity 10 and the second mold cavity 12 are defined between afirst mold part 14 and a second mold part 16 during the closed-moldintervals of inaccessibility for repositioning of the articles while themold is closed, as shown in views A and F of FIGS. 1, 2 and 3. A spacebetween the first and second mold parts 14, 16 for repositioning of thearticles is accessible only during open-mold periods while the mold isopened by separation of the first and second mold parts 14, 16, as shownin views B through E of FIGS. 1, 2 and 3.

A first article 18 is formed in the first mold cavity 10 by injectionmolding during a first closed-mold interval, as shown in FIG. 1A. After,the injection-molded first article 18 has cooled sufficiently, the firstand second mold parts 14, 16 are separated to open the mold. When thefirst and second mold parts 14, 16 are separated the first article 18 isretained in the first-mold-cavity-defining portion of the second moldpart 16, as shown in FIG. 1B.

At the beginning of a first open-mold period after the first closed-moldinterval, as shown in FIG. 1B, a common robot arm 20 is moved into thespace between the separated first and second mold parts 14, 16. Therobot arm 20 includes first, second, third and fourth extendableattachment mechanisms 22, 24, 26 and 28 that are so positioned on therobot arm 20 that when the robot arm 20 is moved from outside of thespace between the separated first and second mold parts 14, 16 to apredetermined depth of penetration between the mold parts 14, 16, asshown in FIG. 1B, the first and second attachment mechanisms 22, 24 aredisposed at a first mold-cavity position 10′ adjacent those portions ofthe separated first and second mold parts 14, 16 that define the firstmold cavity 10 when the mold is closed, and the third and fourth secondattachment mechanisms 26, 28 are disposed at a second mold-cavityposition 12′ adjacent those portions of the separated first and secondmold parts 14, 16 that define the second mold cavity 12 when the mold isclosed.

After the robot arm 20 is moved to the predetermined depth ofpenetration into the space between the separated first and second moldparts 14, 16, the second attachment mechanism 24 is extended to attachonto the first article 18, as shown in FIG. 1C.

The second attachment mechanism 24 is then retracted to withdraw theattached first article 18 from the second mold part 16, as shown in FIG.1D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 14, 16 to move the attached first article 18from the first position 10′ to outside of the space between theseparated first and second mold parts 14, 16, as shown in FIG. 1E.

The mold is then closed, as shown in FIG. 1F, to commence a secondclosed-mold interval of inaccessibility; whereupon the robot arm 20 isrotated 180 degrees so that the first article 18 attached to the secondattachment mechanism 24 of the robot arm 20 assumes the position shownin FIG. 2A.

During the second closed-mold interval, as further shown in FIG. 2A, asecond article 30 is formed in the first mold cavity 10 by injectionmolding. After, the injection-molded second article 30 has cooledsufficiently, the first and second mold parts 14, 16 are separated toopen the mold. When the first and second mold parts 14, 16 are separatedthe second article 30 is retained in the first-mold-cavity-definingportion of the second mold part 16, as shown in FIG. 2B.

At the beginning of a second open-mold period after the secondclosed-mold interval, as shown in FIG. 2B, the robot arm 20 is againmoved to the predetermined depth of penetration into the space betweenthe separated first and second mold parts 14, 16 to move the firstarticle 18 attached to the second attachment mechanism 24 to the secondmold-cavity position 12′ and to move the third attachment mechanism 26to the first mold-cavity position 10′. All of such movements aresimultaneous.

Next, the second attachment mechanism 24 is extended to place the firstarticle 18 in the portion of the first mold part 14 that partiallydefines the second mold cavity 12; and the third attachment mechanism 26is extended to attach onto the second article 30, as shown in FIG. 2C.

Next, the second attachment mechanism 24 releases the first article 18,which remains in the portion of the first mold part 14 that partiallydefines the second mold cavity 12 while the second attachment mechanism24 is retracted; and the third attachment mechanism 26 is retracted towithdraw the attached second article 30 from the second mold part 16, asshown in FIG. 2D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 14, 16 to move the attached second article30 from the first position 10′ to outside of the space between theseparated first and second mold parts 14, 16, as shown in FIG. 2E.

The mold is then closed, as shown in FIG. 2F, to commence a thirdclosed-mold interval of inaccessibility; whereupon the robot arm 20 isrotated 180 degrees so that the second article 30 attached to the thirdattachment mechanism 26 of the robot arm 20 assumes the position shownin FIG. 3A.

Referring to FIGS. 2B through 2E, the robot arm 20 moves with onecontinuous movement from outside of the space between the separatedfirst and second mold parts 14, 16 to the predetermined depth ofpenetration in such space where the common robot arm 20 both releasesthe first article 18 at the second mold-cavity position 12′ and attachesonto the second article 30 at the first mold cavity position 10′; andfrom the predetermined depth of penetration the common robot arm 20moves with one continuous movement to outside of such space.

In an embodiment alternative to that shown in FIGS. 2B through 2E, theattachment mechanisms 22, 24, 26, 28 are not extended from the robot arm20 in order to attach onto an article or in order to place an article ina cavity-defining portion of a mold part while the robot arm remains ina stationary lateral position, as described above, but instead the robotarm 20 is moved laterally toward and away from the respective separatedfirst and second mold parts 14, 16 in order to enable the respectiveattachment mechanisms 22, 24, 26, 28 to attach onto an article or toplace an article in a cavity-defining portion of a mold part.

During the third closed-mold interval, as further shown in FIG. 3A, athird article 32 is formed in the first mold cavity 10 by injectionmolding; and the first article 18 is combined with a second component 34of a product 36 by forming the second component 36 in the second moldcavity 12 by injection molding. The first article 18, the second article30 and the third article 32 are identical. After, the injection-moldedthird article 32 and the injection molded second component 34 of theproduct 36 have cooled sufficiently, the first and second mold parts 14,16 are separated to open the mold. When the first and second mold parts14, 16 are separated the third article 32 is retained in thefirst-mold-cavity-defining portion of the second mold part 16 and theproduct 36 is retained in the second-mold-cavity-defining portion of thesecond mold part 16, as shown in FIG. 3B.

At the beginning of a third open-mold period after the secondclosed-mold interval, as shown in FIG. 3B, the robot arm 20 is againmoved to the predetermined depth of penetration into the space betweenthe separated first and second mold parts 14, 16 to move the secondarticle 30 attached to the third attachment mechanism 26 to the secondmold-cavity position 12′, to move the second attachment mechanism 24 tothe first mold-cavity position 10′ and to move the fourth attachmentmechanism 28 to the second mold cavity position 12′. All of suchmovements are simultaneous.

Next, the fourth attachment mechanism 28 is extended to attach onto theproduct 36 that includes the first article 18; the third attachmentmechanism 26 is extended to place the second article 30 in the portionof the first mold part 14 that partially defines the second mold cavity12; and the second attachment mechanism 24 is extended to attach ontothe third article 32, as shown in FIG. 3C.

Next, the fourth attachment mechanism 28 is retracted to withdraw theattached product 36 that includes the first article 18 from the secondmold part 16; the third attachment mechanism 26 releases the secondarticle 30, which remains in the portion of the first mold part 14 thatpartially defines the second mold cavity 12 while the second attachmentmechanism 24 is retracted; and the second attachment mechanism 24 isretracted to withdraw the attached third article 32 from the second moldpart 16, as shown in FIG. 3D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 14, 16 to simultaneously move both theattached product 36 that includes the first article 18 from the secondposition 12′ and the attached third article 32 from the first position10′ to outside of the space between the separated first and second moldparts 14, 16, as shown in FIG. 3E.

The mold is then closed, as shown in FIG. 3F, to commence a fourthclosed-mold interval of inaccessibility; whereupon the fourth attachmentmechanism 28 releases the product 36 and then the robot arm 20 isrotated 180 degrees so that the third article 32 attached to the secondattachment mechanism 24 is reoriented for movement to the secondmold-cavity position 12′ within the space between the separated moldparts 14, 16 during a fourth period of accessibility following the thirdinterval of inaccessibility. During the fourth period (not shown) thesecond article 30 is repositioned in the same manner as the firstarticle 18 is repositioned during the third period, the third article 32is repositioned in the same manner as the second article 30 isrepositioned during the third period and a fourth article (not shown) isrepositioned in the same manner as the third article 32 is repositionedduring the third period.

Referring to FIGS. 4A through 4F, 5A through 5F, 6A through 6F and 7Athrough 7F, a second embodiment of the repositioning method of thepresent invention is performed during an injection molding process inwhich a multi-component product having an insert as its first componentis produced by injection molding a second component of the product in afirst mold cavity 40 containing the insert and repositioning thecombined insert and injection-molded second component to a second moldcavity 42 in which a third component of the product is formed incombination with the insert and the second component by injectionmolding the third component. The insert is not necessarily formed byinjection molding. The insert, or first component of the product, isreferred to the following description of this second embodiment as an“article”.

The first mold cavity 40 and the second mold cavity 42 are definedbetween a first mold part 44 and a second mold part 46 duringclosed-mold intervals of inaccessibility for repositioning of thearticles while the mold is closed, as shown in views A and F of FIGS. 4,5, 6 and 7. A space between the first and second mold parts 44, 46 forrepositioning of the articles is accessible only during open-moldperiods while the mold is opened by separation of the first and secondmold parts 44, 46, as shown in views B through B of FIGS. 4, 5, 6 and 7.As in the first embodiment described above with reference to FIGS. 1Athrough 1F, 2A through 2F and 3A through 3F, a common robot arm 20having four extendable attachment mechanisms 22 and 24, 26 and 28 isused to reposition the articles at a first mold-cavity position 40′adjacent those portions of the separated first and second mold parts 44,46 that define the first mold cavity 40 when the mold is closed, and ata second mold-cavity position 42′ adjacent those portions of theseparated first and second mold parts 44, 46 that define the second moldcavity 42 when the mold is closed.

During a first closed-mold interval of inaccessibility, as shown in FIG.4A, a first article 48 that was placed in the first mold cavity 40during a previous period of accessibility is combined with a secondcomponent 50 of a product by forming the second component 50 in thefirst mold cavity 40 by injection molding and a second article 52 isattached to the first attachment mechanism 22 of the common robot arm20. After the injection-molded second component 50 of the product thatincludes the first article 48 has cooled sufficiently, the first andsecond mold parts 44, 46 are separated to open the mold. When the firstand second mold parts 44, 46 are separated, the second component 50 thatis combined with the first article 48 is retained in thefirst-mold-cavity-defining portion of the second mold part 46, as shownin FIG. 4B.

At the beginning of a first open-mold period after the first closed-moldinterval, as shown in FIG. 4B, the common robot arm 20 is moved fromoutside of the space between the separated first and second mold parts44, 46 to a predetermined depth of penetration into the space betweenthe mold parts 44, 46 where the first and second attachment mechanisms22, 24 are disposed at a first mold-cavity position 40′ adjacent thoseportions of the separated first and second mold parts 44, 46 that definethe first mold cavity 40 when the mold is closed, and the third andfourth second attachment mechanisms 26, 28 are disposed at a secondmold-cavity position 42′ adjacent those portions of the separated firstand second mold parts 44, 46 that defme the second mold cavity 42 whenthe mold is closed.

After the robot arm 20 is moved to the predetermined depth ofpenetration into the space between the separated first and second moldparts 44, 46, the first attachment mechanism 22 is extended to place theattached second article 52 article in the portion of the first mold part44 that partially defines the first mold cavity 40; and the secondattachment mechanism 24 is extended to attach onto the first article 48,as shown in FIG. 4C.

Next, the first attachment mechanism 22 releases the second article 52,which remains in the portion of the first mold part 44 that partiallydefines the first mold cavity 42 while the first attachment mechanism 22is retracted; and the second attachment mechanism 24 is retracted towithdraw the attached first article 48 from the second mold part 46, asshown in FIG. 4D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 44, 46 to move the attached first article 48and the second component 50 combined therewith from the first position40′ to outside of the space between the separated first and second moldparts 44, 46, as shown in FIG. 4E.

The mold is then closed, as shown in FIG. 4F, to commence a secondclosed-mold interval of inaccessibility; whereupon the robot arm 20 isrotated 180 degrees so that the first article 48 attached to the secondattachment mechanism 24 of the robot arm 20 assumes the position shownin FIG. 5A.

During the second closed-mold interval, as further shown in FIG. 5A, asecond component 54 of another product of which the second article 52 isthe first component, is formed in the first mold cavity 40 by injectionmolding and a third article 56 is attached to the fourth attachmentmechanism 28 of the common robot arm 20. After, the injection-moldedsecond component 54 of the product that includes the second article 52has cooled sufficiently, the first and second mold parts 44, 46 areseparated to open the mold. When the first and second mold parts 44, 46are separated the second component 54 that is combined with the secondarticle 52 is retained in the first-mold-cavity-defining portion of thesecond mold part 46, as shown in FIG. 5B.

At the beginning of a second open-mold period after the secondclosed-mold interval, as shown in FIG. 5B, the robot arm 20 is againmoved to the predetermined depth of penetration into the space betweenthe separated first and second mold parts 44, 46 to move the firstarticle 48 attached to the second attachment mechanism 24 to the secondmold-cavity position 42′, to move the third article 56 attached to thefourth attachment mechanism 28 to the first mold-cavity position 40′ andto move the third attachment mechanism 26 to the first mold-cavityposition 40′. All of such movements are simultaneous.

Next, the second attachment mechanism 24 is extended to place theattached first article 48 and the second component 50 combined therewithin the portion of the first mold part 44 that partially defines thesecond mold cavity 42, the third attachment mechanism 26 is extended toattach onto the second article 52 having the second component 54combined therewith; and the fourth attachment mechanism 28 is extendedto place the attached third article 56 in the portion of the first moldpart 44 that partially defines the first mold cavity 40, as shown inFIG. 5C.

Next, the second attachment mechanism 24 releases the first article 48and the second component 50 combined therewith, which remain in theportion of the first mold part 44 that partially defines the second moldcavity 42 while the second attachment mechanism 24 is retracted; thethird attachment mechanism 26 is retracted to withdraw the attachedsecond article 52 and the second component 56 combined therewith fromthe second mold part 46; and the fourth attachment mechanism 28 releasesthe third article 56, which remains in the portion of the first moldpart 44 that partially defines the first mold cavity 40 while the fourthattachment mechanism 28 is retracted, as shown in FIG. 5D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 44, 46 to move the attached second article52 having the second component 54 combined therewith from the firstposition 10′ to outside of the space between the separated first andsecond mold parts 44, 46, a s shown in FIG. 5E.

The mold is then closed, as shown in FIG. 5F, to commence a thirdclosed-mold interval of inaccessibility; whereupon the robot arm 20 isrotated 180 degrees so that the second article 52 attached to the thirdattachment mechanism 26 of the robot arm 20 assumes the position shownin FIG. 6A.

Referring to FIGS. 5B through 5E, the robot arm 20 moves with onecontinuous movement from outside of the space between the separatedfirst and second mold parts 44, 46 to the predetermined depth ofpenetration in such space where the common robot arm 20 both releasesthe first article 48 at the second mold-cavity position 42′ and attachesonto the second article 52 at the first mold cavity position 40′; andfrom the predetermined depth of penetration the common robot arm 20moves with one continuous movement to outside of such space.

During the third closed-mold interval, as further shown in FIG. 6A, asecond component 58 of still another product of which the third article56 is the first component, is formed in the first mold cavity 40 byinjection molding; a third component 60 of a product 62, of which thefirst article 48 is the first component, is formed in the second moldcavity 42 by injection molding; and a fourth article 64 is attached tothe first attachment mechanism 22 of the common robot arm 20. The firstarticle 48, the second article 48, the third article 56 and the fourtharticle 64 are identical. After, the injection-molded third component 60of the product 62 that includes the first article 48 and the secondcomponent 58 of the product that includes the third article 56 havecooled sufficiently, the first and second mold parts 44, 46 areseparated to open the mold. When the first and second mold parts 44, 46are separated, the second component 58 that is combined with the thirdarticle 56 is retained in the first-mold-cavity-defining portion of thesecond mold part 46 and the product 62 that includes the first article48 is retained in the second-mold-cavity-defining portion of the secondmold part 46, as shown in FIG. 6B.

At the beginning of a third open-mold period after the third closed-moldinterval, as shown in FIG. 6B, the robot arm 20 is again moved to thepredetermined depth of penetration into the space between the separatedfirst and second mold parts 44, 46 to move the second article 52attached to the third attachment mechanism 26 to the second mold-cavityposition 42′; to move the fourth article 64 attached to the firstattachment mechanism 22 to the first mold-cavity position 40′; to movethe second attachment mechanism 24 to the first mold-cavity position40′; and to move the fourth attachment mechanism 28 to the second moldcavity position 42′. All of such movements are simultaneous.

Next, the fourth attachment mechanism 28 is extended to attach onto theproduct 62 that includes the first article 48; the third attachmentmechanism 26 is extended to place the attached second article 52 and thesecond component 54 combined therewith in the portion of the first moldpart 44 that partially defines the second mold cavity 42; the secondattachment mechanism 24 is extended to attach onto the third article 56;and the first attachment mechanism 22 is extended to place the attachedfourth article 64 in the portion of the first mold part 44 thatpartially defines the first mold cavity 40, as shown in FIG. 6C.

Next, the fourth attachment mechanism 28 is retracted to withdraw theattached product 62 that includes the first article 48 from the secondmold part 46; the third attachment mechanism 26 releases the secondarticle 52 and the second component 54 combined therewith, which remainin the portion of the first mold part 44 that partially defines thesecond mold cavity 42 while the third attachment mechanism 26 isretracted; and the second attachment mechanism 24 is retracted towithdraw the attached third article 56 and the second component 58combined therewith from the second mold part 46; and the firstattachment mechanism 22 releases the fourth article 64, which remains inthe portion of the first mold part 44 that partially defines the firstmold cavity 40 while the first attachment mechanism 22 is retracted, asshown in FIG. 6D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 44, 46 to simultaneously move both theattached product 62 that includes the first article 48, from the secondposition 42′ and the attached third article 56 having the secondcomponent 58 combined therewith from the first position 40′ to outsideof the space between the separated first and second mold parts 44, 46,as shown in FIG. 6E.

The mold is then closed, as shown in FIG. 6F, to commence a fourthclosed-mold interval of inaccessibility; whereupon the fourth attachmentmechanism 28 releases the product 62 and then the robot arm 20 isrotated 180 degrees so that the third article 56 attached to the secondattachment mechanism 24 assumes the position shown in FIG. 7A.

During the fourth closed-mold interval, as further shown in FIG. 7A, asecond component 66 of a further product of which the fourth article 64is the first component, is formed in the first mold cavity 40 byinjection molding; and a third component 67 of the second product 68, ofwhich the second article 52 is the first component, is formed in thesecond mold cavity 42 by injection molding. After, the injection-moldedthird component 67 of the second product 68 that includes the secondarticle 52 and the second component 67 of the product that includes thefourth article 64 have cooled sufficiently, the first and second moldparts 44, 46 are separated to open the mold. When the first and secondmold parts 44, 46 are separated, the second component 66 that iscombined with the fourth article 64 is retained in thefirst-mold-cavity-defining portion of the second mold part 46 and thesecond product 68 that includes the second article 52 is retained in thesecond-mold-cavity-defining portion of the second mold part 46, as shownin FIG. 7B.

At the beginning of a fourth open-mold period after the fourthclosed-mold interval, as shown in FIG. 7B, the robot arm 20 is againmoved to the predetermined depth of penetration into the space betweenthe separated first and second mold parts 44, 46 to move the thirdarticle 56 attached to the second attachment mechanism 24 to the secondmold-cavity position 42′; to move the third attachment mechanism 26 tothe first mold-cavity position 40′; and to move the first attachmentmechanism 22 to the second mold cavity position 42′. All of suchmovements are simultaneous.

Next, the first attachment mechanism 22 is extended to attach onto thesecond product 68 that includes the second article 52; the secondattachment mechanism 24 is extended to place the attached third article56 and the second component 58 combined therewith in the portion of thefirst mold part 44 that partially defines the second mold cavity 42; andthe third attachment mechanism 26 is extended to attach onto the fourtharticle 56, as shown in FIG. 7C.

Next, the first attachment mechanism 22 is retracted to withdraw theattached second product 68 that includes the second article 52 from thesecond mold part 46; the second attachment mechanism 24 releases theattached third article 56 and the second component 58 combinedtherewith, which remain in the portion of the first mold part 44 thatpartially defines the second mold cavity 42 while the second attachmentmechanism 24 is retracted; the third attachment mechanism 26 isretracted to withdraw the attached fourth article 64 and the secondcomponent 66 combined therewith from the second mold part 16, as shownin FIG. 7D.

The robot arm 20 is then moved from the space between the separatedfirst and second mold parts 44, 46 to simultaneously move both theattached second product 68 that includes the second article 52 from thesecond position 42′ and the attached fourth article 64 having the secondcomponent 66 combined therewith from the first position 40′ to outsideof the space between the separated first and second mold parts 44, 46,as shown in FIG. 7E.

The mold is then closed, as shown in FIG. 7F, to commence a fifthclosed-mold interval of inaccessibility; whereupon the first attachmentmechanism 22 releases the second product 68 and then the robot arm 20 isrotated 180 degrees so that the fourth article 64 attached to the thirdattachment mechanism 26 is reoriented for movement to the secondmold-cavity position 42′ within the space between the separated moldparts 44, 46 during a fifth period of accessibility following the fifthinterval of inaccessibility. During the fifth period (not shown) thethird article 56 is repositioned in the same manner as the first article48 is repositioned during the third period, and the fourth article 64 isrepositioned in the same manner as the second article 52 is repositionedduring the third period.

Referring to FIGS. 8A through 8F, 9A through 9F, 10A through 10F, 11Athrough 11F and 12A through 12F, a third embodiment of the repositioningmethod of the present invention is performed during an injection moldingprocess in which a multi-component product is produced by injectionmolding a first component of the product in a first mold cavity 70,repositioning the first component to a second mold cavity 72 in which asecond component of the product is formed in combination with the firstcomponent by injection molding, and repositioning the combined first andsecond components to a third mold cavity 73 in which a third componentof the product is formed in combination with the combined first and thesecond components by injection molding. The first component of theproduct is referred to the following description of this thirdembodiment as an “article”.

The first mold cavity 70, the second mold cavity 72 and the third moldcavity 73 are defined between a first mold part 74 and a second moldpart 76 during closed-mold intervals of inaccessibility forrepositioning of the articles while the mold is closed, as shown inviews A and F of FIGS. 8, 9, 10, 11 and 12. A space between the firstand second mold parts 74, 76 for repositioning of the articles isaccessible only during open-mold periods while the mold is opened byseparation of the first and second mold parts 74, 76, as shown in viewsB through E of FIGS. 8, 9, 10, 11 and 12.

A common robot arm 78 having first, second, third, fourth, fifth andsixth extendable attachment mechanisms 79, 80, 81, 82, 83 and 84 is usedto reposition the articles at a first mold-cavity position 70′ adjacentthose portions of the separated first and second mold parts 74, 76 thatdefine the first mold cavity 70 when the mold is closed, at a secondmold-cavity position 72′ adjacent those portions of the separated firstand second mold parts 74, 76 that define the second mold cavity 72 whenthe mold is closed and at a third mold-cavity position 73′ adjacentthose portions of the separated first and second mold parts 74, 76 thatdefine the third mold cavity 73 when the mold is closed. Referring toFIGS. 13A through 13D, the second and fourth attachment mechanisms 80,82 are mounted on a first member 86 that is rotatable for interchangingthe relative positions of the second and fourth attachment mechanisms80, 82 on the robot arm 78 and the third and fifth attachment mechanisms81, 83 are mounted on a second member 87 that is rotatable forinterchanging the positions of the third and fifth attachment mechanisms81, 83 on the robot arm 78, as shown in FIG. 13C. Also, the robot arm 78is rotatable, as shown in FIG. 13D, for inversely interchanging thepositions of the attachment mechanisms 79, 81, 83 on one side of therobot arm 78 with the positions of the attachment mechanisms 80, 82, 84on the other side of the robot arm 78.

During a first closed-mold interval of inaccessibility, as shown in FIG.8A, a first article 90 is formed in the first mold cavity 70 byinjection molding. After the injection-molded first article 90 hascooled sufficiently, the first and second mold parts 74, 76 areseparated to open the mold. When the first and second mold parts 74, 76are separated, the first article 90 is retained in thefirst-mold-cavity-defining portion of the second mold part 76, as shownin FIG. 8B.

At the beginning of a first open-mold period after the first closed-moldinterval, as shown in FIG. 8B, the common robot arm 78 is moved fromoutside of the space between the separated first and second mold parts74, 76 to a predetermined depth of penetration into the space betweenthe mold parts 74, 76 where the first and second attachment mechanisms79, 80 are disposed at the first mold-cavity position 70′, the third andfourth attachment mechanism 81, 82 are disposed at the secondmold-cavity position 72′ and the fifth and sixth attachment mechanisms83, 84 are disposed at the third mold-cavity position 73′.

After the robot arm 78 is moved to the predetermined depth ofpenetration into the space between the separated first and second moldparts 74, 76, the second attachment mechanism 80 is extended to attachonto the first article 90, as shown in FIG. 8C.

The second attachment mechanism 80 is then retracted to withdraw theattached first article 90 from the second mold part 76, as shown in FIG.8D.

The robot arm 78 is then moved from the space between the separatedfirst and second mold parts 74, 76 to move the attached first article 90from the first position 70′ to outside of the space between theseparated first and second mold parts 74, 76, as shown in FIG. 8E.

The mold is then closed, as shown in FIG. 8F, to commence a secondclosed-mold interval of inaccessibility; whereupon the first member 86is rotated 180 degrees and the robot arm 78 is rotated 180 degrees sothat the first article 90 attached to the second attachment mechanism 80mounted on the first member 86 of the robot arm 78 assumes the positionshown in FIG. 9A.

During the second closed-mold interval, as further shown in FIG. 9A, asecond article 91 is formed in the first mold cavity 70 by injectionmolding. After, the injection-molded second article 91 has cooledsufficiently, the first and second mold parts 74, 76 are separated toopen the mold. When the first and second mold parts 74, 76 are separatedthe second article 91 is retained in the first-mold-cavity-definingportion of the second mold part 76, as shown in FIG. 9B.

At the beginning of a second open-mold period after the secondclosed-mold interval, as shown in FIG. 9B, the robot arm 78 is againmoved to the predetermined depth of penetration into the s pace betweenthe separated first and second mold parts 74, 76 to move the firstarticle 90 attached to the second attachment mechanism 80 to the secondmold-cavity position 72′ and to move the fifth attachment mechanism 83to the first mold-cavity position 70′. All of such movements aresimultaneous.

Next, the second attachment mechanism 80 is extended to place the firstarticle 90 in the portion of the first mold part 74 that partiallydefines the second mold cavity 72; and the fifth attachment mechanism 83is extended to attach onto the second article 911, as shown in FIG. 9C.

Next, the second attachment mechanism 80 releases the first article 90,which remains in the portion of the first mold part 74 that partiallydefines the second mold cavity 72 while the second attachment mechanism80 is retracted; and the fifth attachment mechanism 83 is retracted towithdraw the attached second article 91 from the second mold part 76, asshown in FIG. 9D.

The robot arm 78 is then moved from the space between the separatedfirst and second mold parts 74, 76 to move the attached second article91 from the first position 70′ to outside of the space between theseparated first and second mold parts 74, 76, as shown in FIG. 9E.

The mold is then closed, as shown in FIG. 9F, to commence a thirdclosed-mold interval of inaccessibility; whereupon the second member 87is rotated 180 degrees and the robot arm 78 is rotated 180 degrees sothat the second article 91 attached to the fifth attachment mechanism 83mounted on the second member 87 of the robot arm 78 assumes the positionshown in FIG. 10A.

Referring to FIGS. 9B through 9E, the robot arm 78 moves with onecontinuous movement from outside of the space between the separatedfirst and second mold parts 74, 76 to the predetermined depth ofpenetration in such space where the common robot arm 78 both releasesthe first article 90 at the second mold-cavity position 72′ and attachesonto the second article 91 at the first mold cavity position 70′; andfrom the predetermined depth of penetration the common robot arm 78moves with one continuous movement to outside of such space.

In an embodiment alternative to that shown in FIGS. 9B through 9E, theattachment mechanisms 79, 80, 81, 82, 83, 84 are not extended from therobot arm 78 in order to attach onto an article or in order to place anarticle in a cavity-defining portion of a mold part while the robot armremains in a stationary lateral position, as described above, butinstead the robot arm 78 is moved laterally toward and away from therespective separated first and second mold parts 74, 76 in order toenable the respective attachment mechanisms 79, 80, 81, 82, 83, 84 toattach onto an article or to place an article in a cavity-definingportion of a mold part.

During the third closed-mold interval, as further shown in FIG. 10A, athird article 92 is formed in the first mold cavity 70 by injectionmolding; and the first article 90 is combined with a second component 93of a product by forming the second component 93 in the second moldcavity 72 by injection molding. The first article 90, the second article91 and the third article 92 are identical. After, the injection-moldedthird article 92 and the injection molded second component 93 of theproduct have cooled sufficiently, the first and second mold parts 74, 76are separated to open the mold. When the first and second mold parts 74,76 are separated the third article 92 is retained in thefirst-mold-cavity-defining portion of the second mold part 76 and thefirst article 90 and the second component 93 combined therewith areretained in the second-mold-cavity-defining portion of the second moldpart 76, as shown in FIG. 10B.

At the beginning of a third open-mold period after the third closed-moldinterval, as shown in FIG. 10B, the robot arm 78 is again moved to thepredetermined depth of penetration into the space between the separatedfirst and second mold parts 74, 76 to move the second article 91attached to the fifth attachment mechanism 83 to the second mold-cavityposition 72′, to move the second attachment mechanism 80 to the secondmold-cavity position 72′ and to move the fourth attachment mechanism 82to the first mold cavity position 70′. All of such movements aresimultaneous.

Next, the second attachment mechanism 80 is extended to attach onto thefirst article 90 and the second component 93 combined therewith; thefifth attachment mechanism 83 is extended to place the second article 91in the portion of the first mold part 74 that partially defines thesecond mold cavity 72; and the fourth attachment mechanism 82 isextended to attach onto the third article 92, as shown in FIG. 10C.

Next, the second attachment mechanism 80 is retracted to withdraw theattached first article 90 and the second component 93 combined therewithfrom the second mold part 76; the fifth attachment mechanism 83 releasesthe second article 91, which remains in the portion of the first moldpart 74 that partially defines the second mold cavity 72 while the fifthattachment mechanism 83 is retracted; and the fourth attachmentmechanism 82 is retracted to withdraw the attached third article 92 fromthe second mold part 76, as shown in FIG. 10D.

The robot arm 78 is then moved from the space between the separatedfirst and second mold parts 74, 76 to simultaneously move both theattached first article 90 and the second component 93 combined therewithfrom the second position 72′ and the attached third article 92 from thefirst position 70′ to outside of the space between the separated firstand second mold parts 74, 76, as shown in FIG. 10E.

The mold is then closed, as shown in FIG. 10F, to commence a fourthclosed-mold interval of inaccessibility; whereupon the first member 86is rotated 180 degrees and the robot arm 78 is rotated 180 degrees sothat the combination of the first article 90 and the second component 93attached to the second attachment mechanism 80 and the third article 92attached to the fourth attachment mechanism 82 assume the respectivepositions shown in FIG. 11A.

During the fourth closed-mold interval, as further shown in FIG. 11A, afourth article 94 is formed in the first mold cavity 70 by injectionmolding; and the second article 91 is combined with a second component95 of another product by forming the second component 95 in the secondmold cavity 72 by injection molding. After, the injection-molded fourtharticle 94 and the injection molded second component 95 of the otherproduct have cooled sufficiently, the first and second mold parts 74, 76are separated to open the mold. When the first and second mold parts 74,76 are separated the fourth article 94 is retained in thefirst-mold-cavity-defining portion of the second mold part 76 and thesecond article 91 and the second component 95 combined therewith areretained in the second-mold-cavity-defining portion of the second moldpart 76, as shown in FIG. 11B.

At the beginning of a fourth open-mold period after the fourthclosed-mold interval, as shown in FIG. 11B, the robot arm 78 is againmoved to the predetermined depth of penetration into the space betweenthe separated first and second mold parts 74, 76 to move the combinationof the first article 90 and the second component 93 attached to thesecond attachment mechanism 80 to the third mold-cavity position 73′, tomove the third article 92 attached to the fourth attachment mechanism 82to the second mold-cavity position 72′, to move the fifth attachmentmechanism 83 to the second mold-cavity position 72′ and to move thethird attachment mechanism 81 to the first mold cavity position 70′. Allof such movements are simultaneous.

Next, the second attachment mechanism 80 is extended to place the firstarticle 90 and the second component 93 combined therewith in the portionof the first mold part 74 that partially defines the third mold cavity73; the fifth attachment mechanism 83 is extended to attach onto thesecond article 91 and the second component 95 combined therewith; thefourth attachment mechanism 82 is extended to place the third article 92in the portion of the first mold part 74 that partially defines thesecond mold cavity 72; and the third attachment mechanism 81 is extendedto attach onto the fourth article 94, as shown in FIG. 11C.

Next, the second attachment mechanism 80 releases the combination of thefirst article 90 and the second component 93, which remains in theportion of the first mold part 74 that partially defines the third moldcavity 73 while the second attachment mechanism 80 is retracted; thefifth attachment mechanism 83 is retracted to withdraw the attachedsecond article 91 and the second component 95 combined therewith fromthe second mold part 76; the fourth attachment mechanism 82 releases thethird article 92, which remains in the portion of the first mold part 74that partially defines the second mold cavity 72 while the fourthattachment mechanism 82 is retracted; and the third attachment mechanism81 is retracted to withdraw the attached fourth article 94 from thesecond mold part 76, as shown in FIG. 11D.

The robot arm 78 is then moved from the space between the separatedfirst and second mold parts 74, 76 to simultaneously move both theattached second article 91 and the second component 95 combinedtherewith from the second position 72′ and the attached fourth article94 from the first position 70′ to outside of the space between theseparated first and second mold parts 74, 76, as shown in FIG. 11E.

The mold is then closed, as shown in FIG. 11F, to commence a fifthclosed-mold interval of inaccessibility; whereupon the second member 87is rotated 180 degrees and the robot arm 78 is rotated 180 degrees sothat the combination of the second article 91 and the second component95 attached to the fifth attachment mechanism 83 and the fourth article94 attached to the third attachment mechanism 81 assume the respectivepositions shown in FIG. 12A.

During the fifth closed-mold interval, as further shown in FIG. 12A, afifth article 96 is formed in the first mold cavity 70 by injectionmolding; the combination of the first article 90 and the secondcomponent 93 is combined with a third component 97 of the product 98 byforming the third component 97 in the third mold cavity 73 by injectionmolding; and the third article 92 is combined with a second component 99of still another product by forming the second component 99 in thesecond mold cavity 72 by injection molding. After, the injection-moldedfifth article 96, the injection molded third component 97 of the product98 and the injection molded second component 99 of the still anotherproduct have cooled sufficiently, the first and second mold parts 74, 76are separated to open the mold. When the first and second mold parts 74,76 are separated the fifth article 96 is retained in thefirst-mold-cavity-defining portion of the second mold part 76, theproduct 98 that includes the first article 90 is retained in thethird-mold-cavity-defining portion of the second mold part 76, and thethird article 92 and the second component 99 combined therewith areretained in the second-mold-cavity-defining portion of the second moldpart 76, as shown in FIG. 12B.

At the beginning of a fifth open-mold period after the fifth closed-moldinterval, as shown in FIG. 12B, the robot arm 78 is again moved to thepredetermined depth of penetration into the space between the separatedfirst and second mold parts 74, 76 to move the sixth attachmentmechanism 84 to the third mold-cavity position 73′, to move thecombination of the second article 91 and the second component 95attached to the fifth attachment mechanism 83 to the third mold-cavityposition 73′, to move the fourth article 94 attached to the thirdattachment mechanism 81 to the second mold-cavity position 72′, to movethe fourth attachment mechanism 82 to the second mold-cavity position72′ and to move the second attachment mechanism 80 to the first moldcavity position 70′. All of such movements are simultaneous.

Next, the sixth attachment mechanism 84 is extended to attach onto theproduct 98 that includes the first article 90; the fifth attachmentmechanism 83 is extended to place the second article 91 and the secondcomponent 95 combined therewith in the portion of the first mold part 74that partially defines the third mold cavity 73; the fourth attachmentmechanism 82 is extended to attach onto the third article 92 and thesecond component 99 combined therewith; the third attachment mechanism81 is extended to place the fourth article 94 in the portion of thefirst mold part 74 that partially defines the second mold cavity 72; andthe second attachment mechanism 80 is extended to attach onto the fiftharticle 96, as shown in FIG. 12C.

Next, the sixth attachment mechanism 84 is retracted to withdraw theattached product 98 that includes the first article 90 from the secondmold part 76; the fifth attachment mechanism 83 releases the combinationof the second article 91 and the second component 95, which remains inthe portion of the first mold part 74 that partially defines the thirdmold cavity 73 while the fifth attachment mechanism 83 is retracted; thefourth attachment mechanism 82 is retracted to withdraw the attachedthird article 92 and the second component 99 combined therewith from thesecond mold part 76; the third attachment mechanism 81 releases thefourth article 94, which remains in the portion of the first mold part74 that partially defines the second mold cavity 72 while the thirdattachment mechanism 81 is retracted; and the second attachmentmechanism 80 is retracted to withdraw the attached fifth article 96 fromthe second mold part 76, as shown in FIG. 11D.

The robot arm 78 is then moved from the space between the separatedfirst and second mold parts 74, 76 to simultaneously move all three ofthe attached product 98 that includes the first article 90 from thethird position 73′, the attached third article 92 and the secondcomponent 99 combined therewith from the second position 72′ and theattached filth article 96 from the first position 70′ to outside of thespace between the separated first and second mold parts 74, 76, as shownin FIG. 12E.

The mold is then closed, as shown in FIG. 12F, to commence a sixthclosed-mold interval of inaccessibility; whereupon the sixth attachmentmechanism 22 releases the product 98 that includes the first article 90and then the first member 86 is rotated 180 degrees and the robot arm 78is rotated 180 degrees so that the combination of the third article 92and the second component 99 attached to the fourth attachment mechanism82 and the fifth article 96 attached to the second attachment mechanism80 are reoriented for movement to the third mold-cavity position 73′ andthe second mold-cavity position 72′ respectively within the spacebetween the separated mold parts 74, 76 during a sixth period ofaccessibility following the sixth interval of inaccessibility. Duringthe sixth period (not shown) the second article 91 is repositioned inthe same manner as the first article 90 is repositioned during the fifthperiod, the third article 92 is repositioned in the same manner as thesecond article 91 is repositioned during the fifth period and the fourtharticle 94 is repositioned in the same manner as the third article 92 isrepositioned during the fifth period.

Referring to FIGS. 14A through 14L, a fourth embodiment of therepositioning method of the present invention is performed during aninjection molding process in which articles that constitute componentsof products are repositioned within a plurality of spaces betweenadjacent mold parts of a stack mold that define mold cavities whenrespective pairs of the mold parts are combined in the course ofproducing multi-component products. These spaces are accessible for suchrepositioning only during respective series of open-mold periods thatare separated by closed-mold intervals of inaccessibility for suchrepositioning. The first component of the product is referred to thefollowing description of this fourth embodiment as an “article”.

A first portion of the stack mold includes a first mold part 102 pairedwith a second mold part 103, which when combined, as shown in FIG. 14F,define a first mold cavity 104 and a second cavity 105; and a secondportion of the stack mold includes a third mold part 107 paired with afourth mold part 108, which when combined, as shown in FIG. 14L, definea third mold cavity 109 and a fourth cavity 110. The first, second,third and fourth mold parts 102, 103, 107, 108 are respectively disposedin seriatim adjacent each other for movement along a common axis.

A first space between the first and second mold parts 102, 103 isaccessible for repositioning of the articles only during a first seriesof open-mold periods while the first portion of the mold is opened byseparation of the first and second mold parts 102, 103, as shown inviews B through E of FIG. 14, with an intervening closed-mold intervalof inaccessibility of the first series being shown in views F through A.A second space between the third and fourth mold parts 107, 108 isaccessible for repositioning of the articles only during a second seriesof open-mold periods while the second portion of the mold is opened byseparation of the third and fourth mold parts 107, 108, as shown inviews H through K of FIG. 14, with an intervening closed-mold intervalof inaccessibility of the second series being shown in views L throughG. The first space is accessible only during a closed-mold interval inthe second series of open-mold periods pertaining to the second space;and the second space is accessible only during a closed-mold interval inthe first series of open-mold periods pertaining to the first space

An article that was formed in the first mold cavity 104 by injectionmolding at the beginning of a closed-mold interval of accessibility ofthe first series, as shown in FIG. 14G, is repositioned to the fourthmold cavity 110, where the article is combined with a second componentof one product by injection molding the second component in the fourthmold cavity 110, as shown in FIG. 14A. Another article that was formedin the third mold cavity 109 by injection molding at the beginning of aclosed-mold interval of accessibility of the second series, as shown inFIG. 14A, is repositioned to the second mold cavity 105, where the otherarticle is combined with a second component of another product byinjection molding the second component in the second mold cavity 105, asshown in FIG. 14G.

The articles are repositioned between the respective mold cavities 104and 110, 109 and 105 by means of a common robot arm 112, which includesfirst, second, third and fourth extendable attachment mechanism 113,114, 115 and 116 that are so positioned on the robot arm 112 that whenthe robot arm 112 is moved from outside of the first space between theseparated first and second mold parts 102, 103 to a predetermined depthof penetration into the first space between the first and second moldparts 102, 103, as shown in FIG. 14B, the first and second attachmentmechanisms 113, 114 are disposed at a first mold-cavity position 104′respectively adjacent those portions of the separated first and secondmold parts 102, 103 that define the first mold cavity 104 when the firstportion of the mold is closed, and the third and fourth attachmentmechanisms 115, 116 are disposed at a second mold-cavity position 105′respectively adjacent those portions of the separated first and secondmold parts 102, 103 that define the second mold cavity 105 when thefirst portion of the mold is closed. The positioning of the attachmentmechanisms 113, 114, 115, 116 on the robot arm 112 is also such thatwhen the robot arm 112 is moved from outside of the second space betweenthe separated third and fourth mold parts 107, 108 to a predetermineddepth of penetration into the second space between the third and fourthmold parts 107, 108, as shown in FIG. 14H, the third and fourthattachment mechanisms 115, 116 are disposed at a third mold-cavityposition 109′ respectively adjacent those portions of the separatedthird and fourth mold parts 107, 108 that define the third mold cavity109 when the second portion of the mold is closed, and the first andsecond attachment mechanisms 113, 114 are disposed at a fourthmold-cavity position 110′ respectively adjacent those portions of theseparated third and fourth mold parts 107, 108 that define the fourthmold cavity 110 when the second portion of the mold is closed.

In accordance with this fourth embodiment of the repositioning method, afirst article 118 is moved from the first mold-cavity position 104′within the first space to outside of both the first space and the secondspace during an open-mold period of the first series of open-moldperiods when the first space between the first pair of the first andsecond mold parts 102, 103 is accessible, while the second space betweenthe second pair of the third and fourth mold parts 107, 108 isinaccessible for repositioning; and the first article 118 subsequentlyis moved from outside of the first space and the second space to thefourth mold-cavity position 110′ within the second space during anopen-mold period of the second series when the second space between thesecond pair of the third and fourth mold parts 107, 108 is accessible,while the first space between the first pair of the first and secondmold parts 102, 103 is inaccessible for repositioning. A more detaileddescription of the fourth embodiment follows:

At the beginning of an open-mold period of the first series after aclosed-mold interval thereof, as shown in FIG. 14B, the first and secondmold parts 102, 103 are separated, whereupon a first article 118 formedin the first mold cavity 104 during the preceding closed-mold intervalof the first series is retained in the first-mold-cavity-definingportion of the second mold part 103 and a product 120 that includes asecond article 122 combined with a second component 124 formed in thesecond mold cavity 105 during the preceding closed-mold interval of thefirst series is retained in the second-mold-cavity-defining portion ofthe second mold part 103; and the common robot arm 112 is moved to thepredetermined depth of penetration into the first space between theseparated first and second mold parts 102, 103 in order to dispose thesecond attachment mechanism 114 of the robot arm 112 at the firstmold-cavity position 104′ and in order to dispose the fourth attachmentmechanism 116 at the second mold-cavity position 105′. In thisembodiment the first article 118 and the second article 122 areidentical.

Next, the second attachment mechanism 114 is extended to attach onto thefirst article 118 and the fourth attachment mechanism 116 is extended toattach onto the product 120 that includes the second article 122, asshown in FIG. 14C.

Next, the second attachment mechanism 114 is retracted to withdraw theattached first article 118 from the second mold part 103 and the fourthattachment mechanism 116 is retracted to withdraw the attached product120 that includes the second article 122 from the second mold part 103,as shown in FIG. 14D.

The robot arm 112 is then moved from the first space between theseparated first and second mold parts 102, 103 to simultaneously moveboth the attached first article 118 from the first position 104′ and theattached product 120 that includes the second article 122 from thesecond position 105′ to outside of the first space between the separatedfirst and second mold parts 102, 103, as shown in FIG. 14E.

The first portion of the mold is then closed, as shown in FIG. 14F, tocommence a another closed-mold interval of inaccessibility of the firstseries; whereupon the fourth attachment mechanism 116 releases theproduct 120 that includes the second article 122 and then the robot arm118 is rotated 180 degrees so that the first article 118 attached to thesecond attachment mechanism 114 of the robot arm 112 assumes theposition shown in FIG. 14G.

At the beginning of a subsequent open-mold period of the second series,as shown in FIG. 14G, the third and fourth mold parts 107, 108 areseparated, whereupon a third article 126 formed in the third mold cavity109 during the preceding closed-mold interval of the second series isretained in the third-mold-cavity-defining portion of the third moldpart 107 and a product 128 that includes a fourth article 130 combinedwith a second component 132 formed in the fourth mold cavity 110 duringthe preceding closed-mold interval of the second series is retained inthe fourth-mold-cavity-defining portion of the third mold part 107; andthe common robot arm 112 is moved to the predetermined depth ofpenetration into the second space between the separated third and fourthmold parts 107, 108 in order to move the first article 118 attached tothe second attachment mechanism 114 to the fourth mold-cavity position110′, in order to dispose the third attachment mechanism 115 at thethird mold-cavity position 109′ and in order to dispose the firstattachment mechanism 113 at the fourth mold-cavity position 110′. Thethird article 126 and the fourth article 130 are identical to the firstarticle 118 and the second article 120.

Next, the second attachment mechanism 114 is extended to place the firstarticle 118 in the portion of the fourth mold part 108 that partiallydefines the fourth mold cavity 110; the third attachment mechanism 115is extended to attach onto the third article 126 and the firstattachment mechanism 113 is extended to attach onto the product 128 thatincludes the fourth article 130, as shown in FIG. 14I.

Next, the second attachment mechanism 114 releases the first article118, which remains in the portion of the fourth mold part 108 thatpartially defines the fourth mold cavity 110 while the second attachmentmechanism 114 is retracted; the third attachment mechanism 115 isretracted to withdraw the attached third article 126 from the third moldpart 107 and the first attachment mechanism 113 is retracted to withdrawthe attached product 128 that includes the fourth article 130 from thethird mold part 107, as shown in FIG. 14J.

The robot arm 112 is then moved from the second space between theseparated third and forth mold parts 107, 108 to simultaneously moveboth the attached third article 126 from the third position 109′ and theattached product 128 that includes the fourth article 130 from thefourth position 110′ to outside of the second space between theseparated third and fourth mold parts 107, 108, as shown in FIG. 14K.

The second portion of the mold is then closed, as shown in FIG. 14L, tocommence another closed-mold interval of inaccessibility of the secondseries; whereupon the first attachment mechanism 113 releases theproduct 128 that includes the fourth article 130 and then the robot arm112 is rotated 180 degrees so that the third article 126 attached to thethird attachment mechanism 115 of the robot arm 112 assumes the positionshown for article 126′ in FIG. 14A. The repositioning method continuesthrough another sequence of steps such as shown in FIGS. 14A through14L, with a product that includes the first article 118 being moved fromthe fourth mold cavity position 110′ to outside of the second spaceduring the next open-mold period of the second series by a step such asthat shown in FIG. 14K, in which the product 128 that includes thefourth article 130 is so moved.

It is noted from FIGS. 14A through 14L that except for repositioning thearticles between positions within spaces between different pairs of moldparts, the fourth embodiment of the repositioning method is quitesimilar to the first embodiment of repositioning method shown in FIGS 1Athrough 1F, FIGS. 2A through 2F and FIGS. 3A through 3F, wherein duringan open-mold period (a) two different articles are moved simultaneouslyby a common robot arm from different mold cavity positions within aspace between separated mold parts to outside of such space; and (b) onearticle is moved from outside of such space to a given mold-cavityposition within such space by means of a common robot arm that is alsoused to move another article from the same mold-cavity position tooutside of such space. The other features of the first embodimentdescribed hereinabove that are not incompatible with the fourthembodiment are also included in the fourth embodiment.

Utilization of the fourth embodiment of the repositioning method of thepresent invention with a desynchronously opened stack mold, as describedabove, enables articles to be repositioned more quickly in that onearticle can be repositioned into a space in a different portion of themold than the portion from which the one article was moved while anotherarticle that was subsequently injection-molded in the portion of thestack mold from which the one article was moved is cooling.

All of the embodiments of the repositioning method of the presentinvention described herein can be practiced with the desynchronouslyopened stack mold described in U.S. Pat. No. 4,990,299 to Jens OleSorensen.

The design and operations of the robot arms are not limited to theparticular embodiments described herein, inasmuch as the art includesmany different types of robot arm designs and operations that canprovide the same results as attained by the embodiments of the robotarms described herein.

The respective components of the multi-component products may be made ofdifferent plastic materials and/or of different colors. There is noupper limitation as to the number of components; and the relativepositioning of the different mold cavities may be other than the linearalignments shown in the Drawing.

During the injection-molding processes in which the repositioningmethods of the present invention are utilized, additional products canalso be injection molded between the same pair(s) of mold parts as areused to form multi-component products through utilization of therepositioning methods. Such additional products may be either singlecomponent products or multi-component products; and such additionalmulti-component products may include a plurality of identical and/ordissimilar products of which one or more components are repositioned inaccordance with the present invention.

The repositioning methods of the present invention can be utilized withinjection-molding processes other than those described herein. Forexample the repositioning methods of the present invention can beutilized with a core-back injection molding process, in which a core isretracted following injection of a first plastic material into a moldcavity in order to enable injection of a second plastic material intothe mold cavity without separating the mold parts between suchinjections of the plastic material, such that at least one of thecomponents of the multi-component product formed through utilization ofthe repositioning method may be multi-colored and/or composed ofdifferent materials. In an exemplary embodiment using a mold having twocore-back mold cavities, a first component formed in the first core-backmold cavity can be a multi-colored and/or multi-material component thatis removed from the space between the mold parts during a firstopen-mold period of accessibility; and after the first componentsubsequently is moved to the position of the second core-back cavityduring a second open-mold period of accessibility, a secondmulti-colored and/or multi-material component is formed in the secondcore-back mold cavity during a subsequent closed-mold interval ofinaccessibility, A core-back injection-molding process for a stack moldis described in U.S. Pat. No. 5,049,343 to Jens Ole Sorensen.

During an intermediate closed-mold interval during which a component ofan uncompleted multi-component product is outside of the space betweenthe mold parts as a result of being repositioned in accordance with thepresent invention, such component can be subjected to an ancillaryprocess that enhances the final product. For example, a product labelcan be affixed to such component; and then after the componentsubsequently has been repositioned within the space between the moldparts a transparent plastic layer can be injection molded over the labelto thereby provide a product having a sealed label. The respectivecomponents of the product can be subjected to a different ancillaryprocesses during each such intermediate closed mold interval in whichthe respective component is outside the space between the mold partsduring the overall injection molding process.

The repositioning methods of the present invention also may be utilizedwith processes other than injection molding in which certain steps arebetter carried out either under or apart from special conditions in aspace that is sealed from the ambient, such as conditions of extremeheat or cold, high or low pressure, high pollution, poisonous air, highradiation or within a centrifuge.

For example an article that has been repositioned during a period ofaccessibility into a space from which the article was removed during aprior period of accessibility may be subjected to a process, such asheat processing or irradiation, that is more effective during aninterval of less accessibility than during a period of accessibility.

In another example, an article that has been moved from a space tooutside of the space during a period of accessibility is subjected to agiven process during an interval of less accessibility while outside ofthe space before being moved back into the space during a subsequentperiod of accessibility.

The advantages specifically stated herein do not necessarily apply toevery conceivable embodiment of the present invention. Further, suchstated advantages of the present invention are only examples and shouldnot be construed as the only advantages of the present invention.

While the above description contains many specificities, these shouldnot be construed as limitations on the scope of the present invention,but rather as examples of the preferred embodiments described herein.Other variations are possible and the scope of the present inventionshould be determined not by the embodiments described herein but ratherby the claims and their legal equivalents.

What is claimed is:
 1. A method of repositioning articles within a space that is accessible for said repositioning only during a series of periods that are separated by intervals of less accessibility for said repositioning, comprising the steps of: (a) during a first said period, moving a first article from a first position within said space to outside of said space; and (b) during the first period, moving a second article from outside of said space to a second position within said space; wherein said movement of the first article and said movement of the second article are by means of a common vehicle.
 2. A method according to claim 1, further comprising the step of: (c) during a second period after a said interval of inaccessibility that is subsequent to the first period, moving the first article by means of the common vehicle from outside of said space to the second position.
 3. A method according to claim 2, further comprising the step of: (d) during the second period, moving the second article by means of the common vehicle from the second position to outside of said space.
 4. A method according to claim 1, further comprising the step of: (c) during a second period after a said interval of inaccessibility that is subsequent to the first period, moving the second article by means of the common vehicle from the second position to outside of said space.
 5. A method of repositioning articles within a space that is accessible for said repositioning only during a series of periods that are separated by intervals of less accessibility for said repositioning, comprising the steps of: (a) during a first said period, moving a first article from a first position within said space to outside of said space; and (b) during the first period, moving an identical second article from outside of said space to a second position within said space.
 6. A method according to claim 5, further comprising the step of: (c) during a second period after a said interval of inaccessibility that is subsequent to the first period, moving the first article from outside of said space to the second position.
 7. A method according to claim 5, wherein said movement of the first article and said movement of the second article are by means of a common vehicle.
 8. A method of repositioning articles within a space that is accessible for said repositioning only during a series of periods that are separated by intervals of less accessibility for said repositioning than during said periods, comprising the steps of: (a) during a first said period, moving a first article from a first position within said space to outside of said space; and (b) during a second said period after a said interval of less accessibility that is subsequent to the first period, moving the first article from outside of said space to a second position within said space.
 9. A method according to claim 8, wherein said movements of the first article during steps (a) and (b) are by means of a common vehicle.
 10. A method according to claim 8, further comprising the step of: (c) during the second period, moving the first article from outside of said space to the second position.
 11. A method according to claim 8, further comprising the step of: (c) during the second period, moving a second article from the first position to outside of said space.
 12. A method according to claim 11, further comprising the step of: (d) during a third said period after a said interval of less accessibility that is subsequent to the second period, moving the second article from outside of said space to the second position.
 13. A method according to claim 12, further comprising the steps of: (e) during the third period, moving a third article from the first position to outside of said space; and (f) during a fourth said period after a said interval of less accessibility that is subsequent to the third period, moving the third article from outside of said space to the second position.
 14. A method according to claim 13, wherein step (e) further comprises the step of: (g) moving the first article from the second position to outside of said space simultaneously with said movement of the third article from the first position; wherein said simultaneous movement of the first article and the third article is by means of a common vehicle.
 15. A method according to claim 13, wherein step (f) her comprises the step of: (g) moving the first article from outside of said space to a third position within said space simultaneously with said movement of the third article to the second position; wherein said simultaneous movement of the first article and the third article is by means of a common vehicle.
 16. A method according to claim 15, further comprising the following step during a fifth said period after a said interval of less accessibility that is subsequent to the fourth period: (h) moving the first article, the third article and a fifth article out of said space simultaneously by means of a common vehicle.
 17. A method according to claim 13, further comprising the following step during the fourth period: (g) moving the second article and a fourth article out of said space simultaneously by means of a common vehicle.
 18. A method according to claim 17, further comprising the following step during a fifth said period after a said interval of less accessibility that is subsequent to the fourth period: (h) moving the second article and the fourth article into said space simultaneously by means of a common vehicle.
 19. A method according to claim 13, wherein the first article and the second article are identical articles.
 20. A method according to claim 11, wherein the first article and the second article are identical articles.
 21. A method according to claim 8, further comprising the steps of: (c) during a third said period after a said interval of less accessibility that is subsequent to the second period, moving the first article from the second position to outside of said space; and (d) during a fourth said period after a said interval of less accessibility that is subsequent to the third period, moving the first article from outside of said space to a third position within said space.
 22. A method according to claim 21, further comprising the steps of: (e) during the second period, moving a second article from the first position to outside of said space; and (f) during the third period, moving the second article from outside of said space to the second position.
 23. A method according to claim 21, wherein during a said interval of less accessibility that is subsequent to the second period and prior to the third period, the first article is combined with a given object.
 24. A method according to claim 23, wherein during a said interval of less accessibility that is subsequent to the fourth period, the first article is further combined with another object.
 25. A method according to claim 8, wherein step (b) further comprises the step of: (c) moving another article from outside of said space to the first position simultaneously with said movement of the first article to the second position; wherein said simultaneous movement of the first article and the other article is by means of a common vehicle.
 26. A method according to claim 25, wherein the first article and the other article are identical articles.
 27. A method according to claim 8, wherein step (a) further comprises the step of: (c) moving another article from a second position within said space to outside of said space simultaneously with said movement of the first article from the first position; wherein said simultaneous movement of the first article and the other article is by means of a common vehicle.
 28. A method according to claim 27, wherein step (a) further comprises the step of: (d) moving a further article from a third position within said space to outside of said space simultaneously with said movement of the first article from the first position; wherein said simultaneous movement of the first article, the other article and the further article is by means of a common vehicle.
 29. A method according to claim 27, wherein the first article and the other article are identical articles.
 30. A method according to claim 8, wherein during a said interval of less accessibility that is subsequent to the second period, the first article is combined with a given object.
 31. A method according to claim 8, wherein during a said interval of less accessibility that is subsequent to the second period, the first article is subjected to a process that is more effective during a said period of less accessibility than during a said period of accessibility.
 32. A method according to claim 8, wherein during a said interval of less accessibility that is between the first period and the second period, the first article is subjected to a given process.
 33. A method according to claim 8, wherein the first period is separated from the second period by only one interval of less accessibility.
 34. A method of repositioning an article within a space that is accessible for the repositioning of articles therein only during a series of periods that are separated by intervals of less accessibility for said repositioning than during said periods, comprising the steps of: (a) during a first said period, moving an article from outside of said space to a first position within said space; (b) during a second period after a said interval of less accessibility that is subsequent to the first period, moving the article from the first position to outside of said space; and (c) during a third said period after a said interval of less accessibility that is subsequent to the second period, moving the article from outside of said space to a second position within said space.
 35. A method according to claim 34, wherein during a said interval of less accessibility that is subsequent to the first period and prior to the second period, the article is combined with a given object.
 36. A method according to claim 35, wherein during a said interval of less accessibility that is subsequent to the third period and prior to a fourth said period, the article is further combined with another object. 